Next up the front end rebuild and fitting new humvee style round headlights and rear quarters panels

The turret design needed to be removable and allow free 360 rotation. We used a steel band and had the turret on castors with a frame to fit over it.

With all the sheet metal on in was time to cut out the doors and add the bull bars.

Nearly done time to bring out the body filler and start to sand.

Nearly 4 months into the project its finally time to take it to the paint shop

Colour of choice is good old Olive drab.

Almost finished product

The beast in action.

In total from planning to finish the project took 6 months and a lot of manhours.It was not without a few hicups, from Bulldog lighting 4 home made smoke grenades with the grinder and nearly burning down the house, to me setting myself on fire after taking out the fuel filter.

One word of caution. GCs are unibody construction and all the stuff you just cut off was a significant portion of the structural rigidity of the design. The tubing you used for shaping the design is way to small to carry the structural loads carried by the previous steel, but if you did a good job of bonding (welding or fastening) the upper frame to the sheet metal and all that to the existing uni-body core, it will go a long ways towards approaching the initial rigidity. That said, you added back a lot of weight, perhaps more than you took off. Be somewhat cautious with your off roading because you are going to put a lot of stress on the sheet metal welds.

I would suggest adding a true roll bar inside for safety in the event of the rollover. GCs are almost 2 tons at the curb, empty.

Very true, if you look at the early frame pictures you can just make out the 2" U-channel that was put in where the old center pillars where, which helps to provide a bot of extra rigidity.
The hummer is not really driven that hard during the game anyway safety dictates driving slow and we have a unimog if a game requires a troop carrier that has good off roading capabilities.
Thanks for all the comments if you are about in nova scotia at the end of the month feel free to see it in action.http://www.pbnation.com/showthread.php?t=3686940